Concrete building structure



Oct. l5, 1940. C, DEUEL CONCRETE BUILDING STRUCTURE 2 Sheets-Sheet lFiled Aug. 9, 1958 Z/ Z0 ZZ 27 Z8 INVENTOR. dwf faa 4x/1.4%( cui. e...XS

0611.15, 1940. r C Q DEUYEL I 2,217,675

CONCRETE BUILING STRUCTURE Filed Aug. 9, 1938 2 Sheets-Sheet 2 a YEDEUEL A TTORNEYS.

IN VEN TOR.

BY www Patented Oct. 15, 1940 UNITED STATES CONCRETE BUILDING STRUCTUREClyde Deuel, Los Angeles,

Calif., assignor to Ed Westberg, Harry Naftalin, and Louis L. Swarthe,

as trustees Application August 9,' 1938, Serial No. 223,840

3 Claims.

This invention relates to building construction and particularlypertains to a concrete building structure and the method of making thesame.

At the present time it is usual practice to provide forms Within whichcementitious material may be poured and allowed to set in producing thewalls and other structural elements of a building when the building ismade of concrete or the like. This procedure requires that the formsmust be subsequently removed in order to prepare the walls or otherelements for nal use. In the event that hollow walls are required it isalso necessary to remove core elements from the walls so that thecavities will be cleared. This procedure requires a. large amount ofequipment which must be set up for producing the wall forms and whichmust be removed after the work has been completed. The labor involved isa considerable item of expense in addition to the fact that the wear andtear upon the forms makes it necessary for them-to require considerablerepair in order to keep them in operating. condition.

It is the principal object of the present invention to provide a methodand means of forming building structures of cementitious material whichcontemplates the use of pre-cast cementitious elements as forms orbacking members, and against which, or around which, additionalcementitious material is placed to produce the wall configuration and tounite withthe pre-cast wall forms to provide a monolithic wall structurehaving a. definite determined strength and being of the shape anddimensions required, the same as though the structural member had beenformed at one time from cementitious material, all of which operationand construction is simple and relatively inexpensive.

The present invention contemplates the construction of pre-cast elementsserving the dual purpose of form structures and permanentbuildingelements, and which pre-cast elements are assembled to provide asuitable building structure and are thereafter covered to a desiredthickness with cementitious material by hand or mechanical appliances,whereby the iinal building structure is produced.

The invention is illustrated by way of example in the accompanyingdrawings, in which:

Figure 1 is an enlarged view in vertical section showing a wall of thetype here disclosed, and further indicating fragmentary portions of aoor and roof.

Fig. 2 is a view in transverse section through the wall as seen throughthe line 2-2 of Figure 1.

Fig. 3 is a view shown at reduced scale indieating a horizontal sectionof wall built according to the structure with which the presentinvention is concerned and particularly discloses a corner structure.

Fig. 4 is a view in plan showing the corner of 5 a wall embodying thepresent invention.

Fig. 5 is a view in horizontal section showing an intermediate Wa11pilaster, indicating the manner in which a. partition element is adaptedthereto. 'I l0 Fig. 6 is a view in vertical position disclosing a oor orroof joist structure.

Fig. 7 is a view in perspective drawn at reduced scale and showing oneof the shell structures.

Fig. 8 is a view in horizontal section showing l5 the method ofassembling the shell structure shown in Fig. '1 around a colunm.

Fig. 9 is a fragmentary view showing the method of utilizing a shellelement in forming a roof and cornice.

Referring more particularly to the drawings, I0 indicates a wallfooting, here shown as comprising a foundation portion I I and avertical portion I2. 'I'he vertical portion may continue horizontally ina iioor I3. The oor level is indicated at 25 I4. Directly above thevertical portion is a horizontal face I5 which is preferably on a planelower than the floor level I4, and provides an abutment I 6 limitinginward movement of thev pre-cast wall elements I1. The pre-cast wallelements Il lcomprise a front wall I8, which is shown as beingrelatively thin in thickness and which is bound along its top by aheader I9 and along opposite vertical edges by studding sections 20.'I'he structure is thus composed of a flat wall I8 bound on three sidesby flanged headers I8 and 20, as particularly shown in Fig. 7 of thedrawings. In this particular form of the invention the upper edge of thepre-cast wall elements I'I is at right angles to the front vertical faceof 40 the wall I8, as indicated at 2i. 'I'he inner face of the header I8is inclined, as indicated at 22-, thus suitably reinforcing the headerI9 at the point of its juncture with the wall portion. The studdingportions of the pre-cast wall element Il flare outwardly and oppositelyfrom the wall I8, and thus when they are arranged side by side in theirpermanently assembled position, as shown in Fig. 2 of the drawings, theywill cause a V-- shaped throat 23 to occur between their outer inclinedfaces 24.

'Ihe wall portions I8 are strengthened by suitable reinforcing elements25. These reinforcing elements are preferably sheets of reticulatedmaterial, such for example as electrically welded 5s mesh, and wheredesired the marginal edges of this mesh are arranged to extend beyondthe edges of the shell, as particularly shown in Fig. '1. By thisarrangement it is possible to use these extending edges as connectingmeans for binding the pre-cast wall elements together prior to applyingcementitious material thereover. The marginal flanges I9 and 20 whichform the joist and studding sections are likewise reinforced and carrylongitudinally extending reinforcing rods 26. When the pre-cast elementsare assembled, it is evident that the reinforcing rods 26 may be tiedtogether, if desired, to hold the pre-cast elements in a desired erectedposition.

The thickness of the pre-cast elements agrees substantially with thewidth of face I5 on the footing, thus the lower face of the pre-castelements rests directly upon the face I5 and is held against inwardmovement by the abutment of the edge face of the studding portions 20with the shoulder I6.

The pre-cast wall elements have preferably been made over a form uponwhich cementitious material has been applied. In order to create theproper strength and texture for the pre-cast element it is desirable toapply the cementitious material by pneumatic force, such as would beobtained by the use of the device shown in U. S.

Patent No. Re. 20,440, issued to Westberg et al.

on the 6th day of July, 1937, and entiud Concrete conveying and mixingmachine. Due to the fact that this type of machine will apply thecementitious material with considerable force, it is evident that themass of material `will be compacted so that a minimum amount of materialmay be used to obtain a maximum strength.

In forming a roof or floor structure in accord- Iance with the teachingsof the present invention,

pre-cast elements 21 are formed having flat wall portions 28, themarginal edges of which are bound by flanges 29 forming joists. Thesemarginal flanges have outwardly inclined faces 30 which, when assembledadjacent to each other, form a V-shaped throat 3|. l

In the forms of the invention shown in Figs. 3 to 6 of the drawings thefundamental theory of the invention is the same as that disclosed inFigs. 1, 2 and '1; however, the shape of the outer faces of the flangeson the pre-cast elements are slightly different. These elements areformed with substantially flat faces 33 interrupted by longitudinalgrooves 34. The longitudinal grooves of contiguous faces 33 are inregister when the forms are disposed in an assembled position, and thusprovide a space into which a key 35 of cementitious material may bepoured or shot to bind the elements together. The portions of the faces33 nearest the edges of the flanges of the pre-cast elements are spacedslightly apartl to form a throat 36 into which cementitious material mayfill and by which a more effective bond will be produced.

As shown in Figs. 3, 4 and 5 of the drawings, it may be desirable toprovide wall and corner posts 31 to` which the pre-cast elements arekeyed, as previouslyfdescribed. Appropriate faces of the posts aea'frmedwith grooves 34 which receive the bondingimaterial. In order to properlytie the pre-cast floor and roof elements 21 to the wall, tie sections 38may be provided, as particularly shown in Fig. 6, and may be interlockedwith sills 39. The tie sections 38 have horizontal slabs 40 and marginaljoist flanges 4|. Certain of these flanges will be assembled in closeproximity to similar joist flanges on the elements 21, as previouslydescribed. The lateral flanges are formed with extension portions 42having downwardly extending lugs 43, which tvwithin grooved recesses 44of the sills 33, and thus hold the entire structure in interlocked 5relation.

By reference to Fig. 8 of the drawings, it will be seen that thepre-cast form elements are arranged around a column, even though theirflange faces are disposed at an angle to the normal square of thecolumn. It will be evident, however, that this arrangement will notpreclude the possibility of a proper practice of the present invention.

Referring particularly to Fig. 9 of the drawings, it will be seen thatthe wall portion IB of a pre-cast element is formed with obliquelydisposed wall members and 5I. by which the form of a roof and itsoverhanging eave may be made. These members receive cementitiousmaterial on both of their sides, as indicated at 62 and 53, and thuscombine with the form to make a monolithic roof structure. Upon thisroof structure tile or other roof covering 54 may be placed.

In forming and using the elements with which the present invention isconcerned it is rst necessary to make the pre-cast form elements ofdesired dimensions. As previously stated, these may be made byforcefully applying cementitious material to the surface of the formuntil the desired thickness has been placed thereon, and which ispreferably placed by the use of pneumatic means,y such as shown in theaforementioned Westberg et al. Patent No. Re. 20,440. The footings I0may then be made and the floor may be poured or shot. It may bedesirable to apply the floor to a rock fill I3. After this has been doneand the horizontal faces I5 have been properly trued up, the pre-castwall elements I1 may then be assembled with relation to each other andwith relation to a wall post 31 or the like. It will be understood thatthe pre-cast elements may be held together by some temporary support orthat they may be tied together by the reticulated material 25, afterwhich the roof elements may be assembled and suitably supported in theirintended nal position. The outer edges of the outermost ceiling elementsmay rest upon the upper faces 2| of the members I9. Cementitiousmaterial is then applied to the outer faces of these assembled elements;this is preferably done by the aid of a machine of the type disclosed inthe Westberg Patent No. Re. 20,440, in which instance the cementitiousmaterial is forcefully applied to the outer surfaces of the portions I8and 28 of the pre-cast elements I1 and 21. It will also be evident thatthe cementitious material is directed into the V-shaped throats 23between the studding flanges 20 and the V-shaped throats 3| between thejoist flanges 29.

Attention is directed to the fact that in forming the wall and roofstructure as shown in Fig. 1, and as shown in Fig. 9, a bond beam 60'isformed above the pre-cast wall elements I1 and against the pre-castceiling elements 21. These bond beams are suitably reinforced byreinforcing 6| and act to cooperate with the footing I2 and the surfacecoatings 46 to construct a cornplete monolithic building structure ofsufficient strength to serve such purposes as are necessary inconnection with the building of a residence, office building orindustrial buildings.

After the cementitious material has been ap- 75 plied to a desiredthickness, the surface of the material, while in a plastic state, maythen be troweled, scraped or otherwise acted upon to give a desiredsurface configuration to it. The material is then allowed to set and toform a homogeneous union with the surface of the precast elements sothat the final building structure will be monolithic in its entirety,tied together by suitable reinforcing elements and having a desiredstrength obtained by the use of a minimum amount of material.

It will also be evident that after the cementitious material has beenapplied to the surface of the structure there will not be any forms toremove since the forms erected were made of cementitious material andwere consolidated within the walls and other parts of the buildingstructure. After the structure has been set it may be desirable to applyinner wall and ceiling slabs 45 which may be tied into position suitablyand will cover the backs of the precast elements Il and 2l so that anydesired interior treatment may then be followed, thus the pre-castelements will be covered on their inner faces by the slabs 45 and on theother faces by the mass of cementitious material generally indicated at4B.

It will thus be seen that the structure here disclosed is entirelyfire-proof, that it may be made without the use of concrete forms andthat when it is complete it will provide a structure having a desiredstrength obtained by the use of. a minimum amount of cementitiousmaterial, forming a monolithic building.

While I have shown the preferred form of my invention and the preferredmethod of producing the same, it is to be understood that variouschanges may be made in the combination, construction and arrangement ofparts of the structure, and that variations may be made in the steps ofthe process by those skilled in the art without departing from thespirit of the invention as claimed.

Having thus described my invention, what I claim and desire to secure byLetters Patent is:

1. A monolithic building structure comprising a plurality of pre-castmembers having a plane .surface for receiving a coating of cementitiousmaterialwalndmarginal flanges along the sids of said plane surface, theend flanges having square faces at right angles to the plane surface andthe side flanges being outwardly flaring whereby when the side flangesof contiguous units are placed in abutting relation to each other an,outwardly presented V-shaped groove Will be provided, said pre-castunit 'having reinforcing therein extending from the marginal flanges totie the flanges of contiguous units together, after which the outer faceof said precast units land the grooves between the units have appliedthereto a surface coating of cementitious material acting to form anouter binding skin for the entire structure and producing a monolithiccasting.

2. A monolithic building structure comprising a plurality of pre-castcementitious units for forming walls and ceilings, said units ofthemselves being of lesser,y strength than required for buildingpurposes, afooting on ich the precast Wall units rest, saidunits presnting an outer flat vertical receiving face, an en flange at the upperend thereof at right angls to said face and extending horizontally, sideanges extending vertically 4along opposite edes of said faceA portionand flaring outwardly nd toward the inside of the wall structure w erebyV-shaped grooves will be formed between contiguous vertical flanges ofpre-cast units, he ceiling units having horizontal slab portion anddownwardly extending flanges which flare outwardly, whereby V-shapedgrooves w' be formed between ilanges of contiguous ceiling units, thelceiling units being disposed wi h the lower edges of their flanges inthe horizntal plane of the end faces of the wall sections and restingthereupon and in offset relation t ereto, said wall being completed bythe appliation of a surface coating of cementitious m -erial to theouter faces of the slabs to fill the V-shaped grooves occurring betweenthe flanges on the slabs and to form a horizontal bond vfbeam upon theupper horizontal faces of the wall slabs and against the vertical facesof the ceiling slabs, whereby the initial strength o f the variouspre-cast slab units will be supplemented to a degree meeting buildingrequirements, and the units will be permanently tied together to form apart of a monolithic building structure.

3. A monolithic building construction comprising a plurality of pre-castcementitious building units forming a slab portion having an outer planeface bounded along the marginal edges by flanges flaring outwardly fromsaid slab, the structure being relatively thin in thickness andincorporating a sheet of reinforcing material, thev edges of whichproject outwardly from the v"edgespf the flanges to provide tying meansbetween the reinforcing material of contiguous units, which units whenassembled form a wall or ceiling structure and over the outer surfacesof which a coating of cementitious material is applied to provide bondribs between the contiguous angular faces of the flanges of the unitsand a surface coating integral therewith, where- 'by the pre-cast units,the intermediate bond ribs and the coating will combine to form amonolithic building structure.

' CLYDE DEUEL.

